OverWatch - Installation - Genie Gen5 (OLD Pre 2022 Harness) - Installation Instructions

OverWatch - Installation - Genie Gen5 (OLD Pre 2022 Harness) - Installation Instructions

Notes
This Tech Doc was written to help customers with very old Genie Gen5 installations
Alert
The latest version of the Genie Gen 5 kit utilises a daughter board with spring loaded contacts that connect to the Genie control board. As we no longer publish or maintain an installation manual for this version kit, it is being published as a Tech Doc here for those customers that still have this old kit version in service.
Warning
Please note that the Software Version 9 update is not compatible with the Pre 2021 harness in this old kit. You will need to update your harness in order to update your software.

Operator Sensor
Installation Steps:
1. Drill two 5.0mm holes to mount the operator sensor (in the position shown in the diagram below).
2. The sensor should be mounted at an angle of 40 degrees.
3. Drill a 4.0mm hole for the PClip installation. 


4. Mount the module in the located position using the supplied positioning wedges, sensor guard, M4 washers, nuts and bolts. 



5. Remove the bottom cover of the joystick enclosure. 


6. Install the Operator Sensor cable gland (in the location shown below) by drilling a 20mm hole


7. Route the operator sensor cable (as shown in the diagram below)



Control Module
Installation Steps:
1. To mount the ECU module, drill the holes (as shown in the diagram below).
2. Use the supplied bolts and nuts, to mount the ECU module to the inside of the control box.


3. From the machine connections loom, cut and crimp the following wires in the table below.
     

Refer to the steps that follow below for more detailed instructions

4. Solder the Black wire from the Overwatch ECU harness, to the White wire (Ground) from the main connector.


5. Locate the Orange wire from the harness coming from the joystick (14-Pin connector) and cut it in half.
6. Solder the Green wire from the Overwatch ECU harness to the Orange wire on the side that is coming from the joystick.
7. Solder the Blue wire from the Overwatch ECU harness onto the other side of the Orange wire that was cut.


8. Install the Red wire from the Overwatch ECU harness to the E-stop terminal 1. 
 

9. Solder the Grey wire from the Overwatch ECU harness onto the Yellow wire, coming from the joystick. 


10. Remove the buzzer and the E-Stop button to have better access to the main circuit board.


11. Identify the pin locations on the circuit board (shown in the image below). 

Detailed instructions on soldering locations will be displayed in the following steps.

12. Solder the Purple wire Overwatch ECU harness, to the pin behind the Drive Select button (shown in the image below).


13. Solder the Orange wire Overwatch ECU harness, to the pin behind the Elevate Select button (shown in the image below).


14. Solder the Blue and Green wires that come from the supplied relay to the pins (shown in the image below)


15. Connect the 8-Pin connector from the laser module and the 12-Pin connector from the machine harness to the control module.


16. After installation is complete, power the machine and press down on the Emergency Stop.
17. While Emergency Stop is active, there should be no presence of power within the Overwatch system.
18. If the Overwatch remains powered, check if the correct side of E-Stop has been used for the Overwatch power.


 
When the installation has been completed, please complete the configuration & installation test below:

Post Installation Configuration
Overview
After the Overwatch has been installed, it must be configured with the correct parameters to suit the machine.

Follow the instructions below to configure the Overwatch.

Minimum system requirements
Any smart phone, tablet or laptop that meets the following requirements:
  1. The device can connect to a Wi-Fi access point
  2. The device has an up to date Firefox or Safari web browser installed (2019 onwards). 

Wi-Fi Connection & Web Page Access
To enable the Wi-Fi connection on the Overwatch to complete the configuration, follow the steps below: 
1. Power down the platform control box with the ESTOP
2. Wait 10 seconds
3. Power up the platform control box with the ESTOP
4. While standing in the operator position, switch on the Overwatch
5. As the welcome chime starts to play, cover the sensor. The LED will flash white then black to acknowledge.
6. Remove your hand from the sensor. The LED will flash white then black to acknowledge.
7. After covering then uncovering the sensor this way 2 more times, "Wi-Fi On" will be announced.
8. On your Wi-Fi enabled device (laptop, tablet, smartphone, etc), show the available wireless networks
9. Select the wireless network (starts with “overwatch”) to connect to the Overwatch
10. When prompted, enter the password “12345678”
11. Open your web browser  (Safari for Apple and Firefox for Android)
12. Enter the following into the address bar http://192.168.4.1 to open the Overwatch main page 
 
Machine Model Selection
Follow the instructions below to configure the Overwatch.
1. Select the Setup option
2. If there is a password field at the bottom of the page, follow the instructions in Change Model Configuration to obtain the password and enter the password field
3. Select the EWP Model from the drop-down list and click Set
4. Click on Proceed to Test to begin the installation test

 

Installation Test
After the model configuration has been set or updated an Installation Test must be performed. This will ensure the installation has been correctly performed and the Overwatch is functioning correctly.

Follow the instructions on the web page to complete the Installation Test.

Change Model Configuration
To reconfigure the Overwatch for a different model requires an authorisation password. The authorisation password is generated from the EQSS website.

Go to the Reconfiguration page and follow the instructions to create an authorisation password.

Settings
The OEM Settings page defines preset OEM parameters
See the sections below for details on each parameter:

Polarity and Input Style
The table below describes each setting: 


Bypass

Date and Time


Connection Schematics